US4478779A - Electrolessly plated mold surface and method of using - Google Patents

Electrolessly plated mold surface and method of using Download PDF

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Publication number
US4478779A
US4478779A US06/526,145 US52614583A US4478779A US 4478779 A US4478779 A US 4478779A US 52614583 A US52614583 A US 52614583A US 4478779 A US4478779 A US 4478779A
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United States
Prior art keywords
mold
composition
metal
exterior surface
nickel
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Expired - Fee Related
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US06/526,145
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English (en)
Inventor
Alexander H. Russell
John L. McClinton
John A. Sergovic
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Burns and Russell Co
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Burns and Russell Co
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Assigned to BURNS & RUSSELL COMPANY THE reassignment BURNS & RUSSELL COMPANY THE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: MC CLINTON, JOHN L., RUSSELL, ALEXANDER H., SERGOVIC, JOHN A.
Priority to US06/526,145 priority Critical patent/US4478779A/en
Priority to GB08421332A priority patent/GB2145366B/en
Priority to CA000461814A priority patent/CA1239519A/fr
Publication of US4478779A publication Critical patent/US4478779A/en
Application granted granted Critical
Assigned to MERCANTILE-SAFE DEPOSIT AND TRUST COMPANY reassignment MERCANTILE-SAFE DEPOSIT AND TRUST COMPANY SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Burns & Russell Company of Baltimore City
Priority to GB08614078A priority patent/GB2175018B/en
Assigned to FIRST NATIONAL BANK OF MARYLAND, THE reassignment FIRST NATIONAL BANK OF MARYLAND, THE SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BURNS & RUSSELL COMPANY OF BALTIMORE CITY, THE
Assigned to SIGNET BANK reassignment SIGNET BANK SECURITY AGREEMENT Assignors: BURNS & RUSSELL COMPANY OF BALTIMORE CITY, THE
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/26—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass heat exchangers or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents

Definitions

  • the present invention relates to a method of forming a molded article and in one embodiment to a casting method wherein a resinous composition such as polyester or an epoxy resin is coated on the exterior surface of an article in order to provide a decorative surface as well as a liquid barrier to the article.
  • a resinous composition such as polyester or an epoxy resin
  • either stainless steel or porcelain coated molds have been employed to provide the smooth surface on molded articles and coatings for castings and building materials including blocks such as concrete or cinderblock.
  • the molding compositions are disclosed in U.S. Pat. Nos. 2,751,775; 3,328,231; 3,632,725, 4,031,289 and 4,329,822, the disclosures of which are hereby incorporated by reference and relied upon.
  • the method of the present invention includes oxidizing the exterior surface of the mold to effect better heat absorption during the curing step.
  • a metal mold such as a cold or hot rolled steel or aluminum but preferably a mild steel metal mold that has its interior molding surface coated with a layer of nickel metal by an electroless deposition process is supplied with a resin composition in flowable form such as polyester resin or an epoxy resin which may contain a pigment and a filler such as sand.
  • a support member such as, for example, the surface of a building block is deposited in the mold and is coated by the resin composition.
  • Support members such as those described in U.S. Pat. No. 4,328,822 may also be employed.
  • the exterior surface of the mold is exposed to heat sufficient to cure the resin composition and to provide a secure attachment of the resin to the exterior surface of the support member.
  • the composition will be hardened and be bonded to the support member such as the porous surface of a masonry unit.
  • the member with the resin material bonded to its surface is removed from the mold and the mold is made ready for re-use.
  • the resulting product gives a uniform appearance to the molded composition without creating an adverse reaction with the mold surfaces, holes in the form or nonuniformities in the smooth surface.
  • the mold of the present invention can be repeatedly used during a substantially great number of curing operations than is possible with porcelain coated molds which offer the required repair or replacement after a single molding cycle.
  • FIG. 1 is a sectional view in elevation of the plated mold element, the resin composition and the building block of the present invention
  • FIG. 2 is a view in elevation, partly in section, of the metal coating operation of the present invention
  • FIG. 3 is a perspective view from the rear of a masked bottom exterior surface of a mold of the present invention.
  • FIG. 4 is a side view in elevation showing another disposition of two mold elements which have their peripheries taped to mask the bottom surfaces thereof prior to being subjected to the electroless deposition process of the present invention.
  • the present invention is particularly useful in the field of coating masonry building units with unsaturated polyester resins such as those disclosed in the first four of the aforementioned U.S. patents, the disclosures of which were incorporated by reference herein and relied upon, it will be understood that other types of support members such as those described in U.S. Pat. No. 4,329,822 may be employed in the present invention.
  • relatively inexpensive masonry units can be provided with a coating surface to produce a decorative, serviceable surface thereon which does not require any finishing after a wall is erected with such blocks.
  • the present invention encompasses the molding of an article, including support members with a mold made according to this invention.
  • the molding compositions disclosed in the aforementioned U.S. patents may be employed with the method of the present invention.
  • FIG. 1 a mold 10 which is preferably made of mild steel and is used for its characteristics of uniformly conducting heat. Mild steel is defined as a steel which has a maximum carbon content no greater than 0.25%. Hot or cold rolled steel or aluminum may also be employed.
  • the mold 10 should be of a shape to accommodate a side edge 23, one surface 22 of a building block 24 a portion of which is illustrated in FIG. 1. Thus, the mold 10 will have four side walls, one of which is indicated at 12 and a bottom exterior surface 14 which is generally planar.
  • the interior surface 16 of the mold 10 has been plated with a nickel coating 18, as described hereinafter.
  • the molding composition which may include a resin, pigment, filler and plasticizer, as described in the aforementioned patents, is milled into a flowable form and then deposited in the mold 10 and spread over the appropriate interior surfaces of the mold.
  • the masonry block 24 is then inserted into the mold and the weight of the block 24 will distribute the composition 20 to a substantially uniform extent over the subjacent surfaces of the mold 10.
  • it may be desirable to constitute the molding composition so that it is substantially in liquid form to facilitate even distribution over the mold surface.
  • a plurality of molds 10 are mounted on a conveyor which is passed through an oven over radiant heaters where the surface 14 is directly exposed to the radiant heat which cures the molding composition 20 so as to bond the composition to the surfaces 23 and 22 of the block 24. After curing, the mold with the bonded resins cured thereto is removed from the mold 10.
  • the mold 10 may be suspended by arms 26 in a plating solution 28 maintained in a tub 30.
  • the electroless plating solution that has been used is as follows:
  • the plating is carried out at a temperature of approximately 185°-200° F. although temperatures in the range of 140°-150° F. have been used.
  • the water used is de-ionized.
  • the bottom surface 14 of the mold should be masked as illustrated in FIG. 3 to prevent the deposition of nickel thereon so that the radiant heat will not be reflected away from the mold.
  • a suitable masking material such as tape 32 may be applied to the bottom surface 14 as illustrated in FIG. 3 before the mold 10 is placed in the solution 28. Lead tape has been used effectively in this case.
  • two molds 10 may be placed back-to-back as illustrated in FIG. 4 with the periphery of the molds masked by a tape 34 so that two molds may be plated simultaneously with their backs 14 masked by the tape 34.
  • the bottom surface should be oxidized after the nickel plating step.
  • the oxidation of the surface 14 may be accomplished in any conventional manner such as by coating the surface with an oxidizing solution and one that preferably also greatly darkens the surface 14. Passing oxygen gas over the surface to be oxidized while applying heat will also oxidize the metal fairly rapidly.
  • any other type of layer on the exterior surface 14 that increases the heat absorbing capacity of the metal of the mold may be employed.
  • a black enamel paint may be used and has proven effective for short periods of time before re-coating with the black paint is necessary. It is important of course that the coating on the surface 14 be non-reflective.
  • the masking tapes 32 and 34 are not employed, and the bottom surface is coated with the nickel by the electroless deposition process, one need merely oxidize the nickel layer to form nickel oxide.
  • While the preferred metal for depositing on the mold surface is nickel, it will be understood by those skilled in this art that other metals may be employed and a number of commercial baths are available and are described in "Metal Finishing Guidebook and Directory", Metals and Plastics Publications, Inc., Hackensack, N.J. (updated yearly), the disclosure of which is incorporated herein by reference and relied upon. The process and character of the electroless platings are discussed in Kirk-Othmer Encyclopedia of Chemical Technology, Third Edition, Volume 8, pages 738-750, John Wiley & Sons (1979), the disclosure of which is incorporated herein by reference and relied upon together with each and every reference cited therein.
US06/526,145 1983-08-24 1983-08-24 Electrolessly plated mold surface and method of using Expired - Fee Related US4478779A (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US06/526,145 US4478779A (en) 1983-08-24 1983-08-24 Electrolessly plated mold surface and method of using
GB08421332A GB2145366B (en) 1983-08-24 1984-08-22 Molding method and apparatus
CA000461814A CA1239519A (fr) 1983-08-24 1984-08-24 Methode et dispositif de moulage
GB08614078A GB2175018B (en) 1983-08-24 1986-06-10 Method of plating a mould

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US06/526,145 US4478779A (en) 1983-08-24 1983-08-24 Electrolessly plated mold surface and method of using

Publications (1)

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US4478779A true US4478779A (en) 1984-10-23

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US06/526,145 Expired - Fee Related US4478779A (en) 1983-08-24 1983-08-24 Electrolessly plated mold surface and method of using

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US (1) US4478779A (fr)
CA (1) CA1239519A (fr)
GB (2) GB2145366B (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4793587A (en) * 1987-09-03 1988-12-27 Leon Berger Core for molding hollow concrete blocks
US5548936A (en) * 1991-11-21 1996-08-27 The Burns & Russell Company Of Baltimore City Composite for turning a corner or forming a column, mold and method for producing glazed unit for such
WO1998001277A1 (fr) * 1996-07-05 1998-01-15 Lupke Manfred Arno Alfred Dispositif de moulage dote de tunnels de moulage non reflechissants
US5750160A (en) * 1994-02-09 1998-05-12 Weber Manufacturing Limited Nickel shell door molds and method of forming same
US5827567A (en) * 1996-11-27 1998-10-27 Molitor; John Peter Game ball mold preparation technique and coating system
US6141933A (en) * 1994-02-25 2000-11-07 Mcclinton; John L Curvilinear masonry building unit, method of applying a glaze composition thereto, a wall corner, a wall corner composite, a column composite or portion thereof, and a mold for applying glaze composition to a curvilinear masonry building unit
US20110290981A1 (en) * 2008-10-06 2011-12-01 Torben Hansen Lining Plate for Lining of Moulding Chambers of Moulding Machines

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2543710A (en) * 1948-01-15 1951-02-27 Westinghouse Electric Corp Process for producing insulating iron oxide coatings
US4031289A (en) * 1976-05-11 1977-06-21 The Burns & Russell Company Of Baltimore City Stain resistant polyester-coated block
US4264646A (en) * 1979-03-12 1981-04-28 Xerox Corporation Selectively electrolessly depositing a metal pattern on the surface of a laminar film
US4364780A (en) * 1980-05-09 1982-12-21 U.S. Philips Corporation Method of providing a metal component with a thermally black surface

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1247734A (en) * 1967-09-25 1971-09-29 Garry R Perkins Abrasion-resistant self-lubricating coating and method

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2543710A (en) * 1948-01-15 1951-02-27 Westinghouse Electric Corp Process for producing insulating iron oxide coatings
US4031289A (en) * 1976-05-11 1977-06-21 The Burns & Russell Company Of Baltimore City Stain resistant polyester-coated block
US4031289B1 (fr) * 1976-05-11 1983-03-29
US4264646A (en) * 1979-03-12 1981-04-28 Xerox Corporation Selectively electrolessly depositing a metal pattern on the surface of a laminar film
US4364780A (en) * 1980-05-09 1982-12-21 U.S. Philips Corporation Method of providing a metal component with a thermally black surface

Non-Patent Citations (6)

* Cited by examiner, † Cited by third party
Title
Ency. of Chem. Tech., Third Ed., vol. 8, pp. 738 750, Gerald Krucik, Electroless Plating. *
Ency. of Chem. Tech., Third Ed., vol. 8, pp. 738-750, Gerald Krucik, "Electroless Plating."
Metal Finishing Guide Book and Directory, "Electroless Plating", Nathan Feldstein, p. 516.
Metal Finishing Guide Book and Directory, Electroless Plating , Nathan Feldstein, p. 516. *
Plating, "Selective Electroless Plating Techniques: A Survey", Aug. 1970, p. 804, Nathan Feldstein.
Plating, Selective Electroless Plating Techniques: A Survey , Aug. 1970, p. 804, Nathan Feldstein. *

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4793587A (en) * 1987-09-03 1988-12-27 Leon Berger Core for molding hollow concrete blocks
US5548936A (en) * 1991-11-21 1996-08-27 The Burns & Russell Company Of Baltimore City Composite for turning a corner or forming a column, mold and method for producing glazed unit for such
US5750160A (en) * 1994-02-09 1998-05-12 Weber Manufacturing Limited Nickel shell door molds and method of forming same
US6141933A (en) * 1994-02-25 2000-11-07 Mcclinton; John L Curvilinear masonry building unit, method of applying a glaze composition thereto, a wall corner, a wall corner composite, a column composite or portion thereof, and a mold for applying glaze composition to a curvilinear masonry building unit
WO1998001277A1 (fr) * 1996-07-05 1998-01-15 Lupke Manfred Arno Alfred Dispositif de moulage dote de tunnels de moulage non reflechissants
US5824351A (en) * 1996-07-05 1998-10-20 Lupke; Manfred A. A. Molding apparatus with non-reflective mold tunnels
US5827567A (en) * 1996-11-27 1998-10-27 Molitor; John Peter Game ball mold preparation technique and coating system
US20110290981A1 (en) * 2008-10-06 2011-12-01 Torben Hansen Lining Plate for Lining of Moulding Chambers of Moulding Machines
US9662706B2 (en) * 2008-10-06 2017-05-30 Disa Industries A/S Lining plate for lining of moulding chambers of moulding machines

Also Published As

Publication number Publication date
GB8421332D0 (en) 1984-09-26
GB8614078D0 (en) 1986-07-16
GB2175018A (en) 1986-11-19
GB2175018B (en) 1987-05-20
GB2145366A (en) 1985-03-27
GB2145366B (en) 1987-05-20
CA1239519A (fr) 1988-07-26

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